In-Line Adhesive Lamination for Custom Stamped Motor Cores
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Solution Overview
Problem
Existing laminated core production methods face challenges in efficiently applying adhesive to sheet metal without reducing shelf-life and allowing for customization, leading to increased waste and limited design options.
Innovation Solution
A machine assembly is used to uncoil sheet metal, apply adhesive, partially cure it, and then stamp and punch it to form laminated cores, with a final curing step to bond the pieces, enabling adhesive application after uncoiling and allowing for customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If adhesive is applied to sheet metal before uncoiling and storage, then the sheet metal can be prepared in advance, but the shelf-life is reduced and waste increases due to adhesive breakdown
Solution Approach 1:
The adhesive is applied to the sheet metal in advance during the uncoiling process, before the stamping and punching operations. This preliminary application allows the adhesive to be positioned correctly on the material while maintaining the ability to store rolls for extended periods without adhesive breakdown, since the adhesive is only applied when the material is actively being processed
Solution Approach 2:
The adhesive application step is extracted and separated from the traditional process where adhesive was applied after cutting. By applying adhesive during the uncoiling process rather than after stamping, the patent eliminates the need to store adhesive-coated material for extended periods, thereby preventing adhesive breakdown while still achieving proper bonding
2Ease of manufacture
If adhesive is applied before stamping and punching, then the process can be simplified, but customization options are limited and design flexibility is reduced
Solution Approach 1:
The system allows dynamic adjustment of adhesive application parameters including pattern, amount, and positioning during the uncoiling process. This enables customization for different core designs while maintaining process simplicity, as the adhesive application can be adapted to various stamping patterns and core configurations without requiring separate processing steps
Solution Approach 2:
The adhesive application apparatus integrated into the uncoiling system serves multiple functions: it can apply adhesive in different patterns, adjust application quantity, and accommodate various sheet metal widths and thicknesses. This multi-functionality provides design customization options while keeping the manufacturing process simple and integrated
3Productivity
If traditional batch processing is used with pre-applied adhesive, then production can be batched efficiently, but adhesive breakdown occurs and waste increases
Solution Approach 1:
The adhesive application is integrated into the continuous uncoiling process, allowing adhesive to be applied continuously as sheet metal passes through the system. This eliminates idle time where adhesive-coated material would sit and potentially degrade, maintaining continuous productive action from uncoiling through adhesive application to stamping, thereby preventing adhesive breakdown and waste
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process extends the shelf-life of adhesive-less sheet metal rolls, reduces waste, and increases design options by allowing for in-line adhesive application and efficient production of laminated cores.
Implementation Method 1
an adhesive application apparatus arranged downstream of the straightener and configured to apply an adhesive to one side of the sheet metal
Implementation Method 2
A first curing apparatus is arranged downstream of the adhesive application apparatus and is configured to partially cure the adhesive
Implementation Method 3
A second curing apparatus is configured to fully cure the adhesive between each stamped metal piece in the stack to form a laminated core
Data Source
AI summary
A machine assembly configured to process a roll of sheet metal to form a laminated core is provided. The assembly includes an uncoiler configured to uncoil the roll of sheet metal. An adhesive application apparatus arranged downstream of the uncoiler is configured to apply an adhesive to the sheet metal. A first curing apparatus is arranged downstream of the adhesive application apparatus and is configured to partially cure the adhesive. A stamp and punch machine is arranged downstream of the first curing apparatus and is configured to stamp and punch the sheet metal to form stamped metal pieces. A stacking apparatus is configured to form a stack of the stamped metal pieces. A second curing apparatus is configured to fully cure the adhesive between each stamped metal piece in the stack to form the laminated core.